Exploring options for extruded snacks and key trends in the extruded snack market
Extruded snacks have become a staple in the global snacking industry, offering endless possibilities in texture, shape, and flavor. From protein-dense crisps to puffed rice, extrusion technology allows manufacturers to meet evolving consumer demands for healthier, more diverse, and convenient snack options. As the market continues to grow, driven by plant-based innovation, clean-label preferences, and functional ingredients, understanding the latest trends and formulation opportunities is essential. Read on to explore the key developments shaping the extruded snack category and the creative potential that extrusion offers for snack formulations.
What are extruded snacks?
Extruded snacks are made using an efficient continuous mechanical process called direct expanded extrusion. This process allows for the development of crisps with various shapes like disks and spherical puffs, which can be eaten alone or incorporated into other snack formulations, like protein bars, cereals or confectionery. Extrusion techniques are chosen by manufacturers not only for the ability to enhance texture and eating experience, but also to add visual appeal and enable precise control over nutritional content, making it ideal for developing better-for-you snacks.
What are the latest trends in the extruded snack market?
Consumer needs are evolving rapidly, driven by consumer demand for health and innovation. Below are the latest trends shaping the extruded snack market:
Functional snacking
Extruded grains and crisps can be high in plant-based protein, low in fat, and gluten-free, ideal for clean-label and better-for-you formulations. These ingredients help brands meet rising consumer demand for functional ingredients in protein-forward or fitness-targeted snack formulations, like protein or energy bars. With customizable textures and nutrient density, extruded ingredients offer a smart solution for manufacturers seeking to create snacks that deliver both indulgence and nutrition, offering consumers a healthier option.
Innovative textures
Extruded ingredients help manufacturers create snack products with distinctive and appealing texture profiles. Whether delivering a chewy texture, crunchy bite, or crispy finish, extruded crisps enhance mouthfeel to add more excitement to the snacking experience. Their versatility allows brands to craft snacks with a unique bite that stands out in the extruded snack market, offering consumers both sensory appeal and nutritional value.
What wholesome ingredients can brands incorporate into snack formulations in extruded form to meet emerging trends?
Extruded pieces allow manufacturers to go beyond traditional textures, flavors and protein sources, offering more innovative and varied product options.
Rice crisps
Light, crunchy inclusions with a neutral taste, rice crisps are a versatile solution ideal for snack bars, granolas, and confectionery treats. Also known as 'crisp rice', they are gluten-free, making them a great fit for allergen-friendly formulations. They can be made using brown or white rice flour in customized shapes and sizes to deliver the texture required and we can add special functional additions to the formulations. Perfect for meeting consumer-driven trends for clean-label snacking, while enhancing visual appeal and crunch.
Soy protein crisps
With up to 90% protein content and a satisfying crunch, PGP’s soy protein crisps work well in protein bars and snacks, offering both texture and nutritional value. As interest in functional snacking continues to rise, soy crisps provide a reliable, plant-based protein source. Soy crisps are well-suited for performance bars, clusters, and snacks targeting fitness-focused or health-conscious consumers.
Pea protein crisps and disks
An allergen-friendly alternative to soy, pea protein crisps and disks offer high protein content with a mild flavor. Their clean-label appeal suits vegan and plant-based formulations, blending seamlessly into protein bars, granola or extruded snacks, to boost enjoyment with enhanced mouthfeel sensations. Available as crunchy crisps, disks or even flake-like shapes, their customizable size and crunch allow manufacturers to create innovative textures which stand out in the market.
Innovative texture solutions for snack manufacturing from PGP
PGP International delivers innovative texture solutions for snack formulating and manufacturing through advanced extrusion technologies tailored to each customer’s needs. With over 30 years of expertise in extrusion, our solutions combine technical precision with creative formulation to produce crisp, crunchy, and high-protein inclusions. Our processes allow for customization of shape, density, and texture across a wide range of ingredients, whilst our collaborative approach allows us to work closely with manufacturers and brands to define formulation goals and co-develop unique texture solutions.
Keen to find out more about how extruded ingredients can help elevate your product formulations? Get in touch with our team today to discuss your ideas or request a sample.